About Sustaining Supply Technology for Manned Spacecraft

By Christian Zschoch

At the present time, space travel is characterized by separately developed technologies of the space-traveling nations. Depending on fixed financial budgets and expensive technology companies, the developed spaceships are strongly designed just for a specific mission profile in order to reduce costs and risks as far as possible. Because of their less sustainable supply concept, these spacecraft allow only a limited mission duration and require regular supply deliveries in addition.

On the other hand side, mission periods continue to lengthen with the planned exploration of Mars, asteroids or other objects that are even more distant. These missions will require high sustainable supply concepts in order to enable autonomous and long-term life support of human mission participants. The now existing solutions do not yet meet these requirements, so the current approach of spacecraft design had to undergo a conceptual review.

The research made in the context of this work led to the design of a new generation of spacecraft, which supports with its optimized hull construction such extended long-term missions in terms of durability, variability and life support. All its embedded biological and chemical processes have, on the one hand, the primary aim to enable humans a long stay in space and, on the other hand, to be independent of an external mission supply. The performed research activities also included the necessary mechanical and energetical functions for which an extreme lifetime extension of up to 60 years was aimed.

• Language: English
• Publisher: Books on Demand
• Release date: Mar 4, 2020
• ISBN: 9783750459076

Christian Zschoch

Christian Zschoch is a freelance scientist, process designer, and software architect. His interest in spaceflight and supply systems dates back to his childhood and he has been developing his skills through research on the subject ever since. He lives near Munich, Germany, in an area characterised by a research and industrial environment that has always inspired and supported him.

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Declaration of Authorship

I hereby declare that the thesis submitted

About Sustaining Supply Technology for Manned Spacecraft

is my own unaided work. All direct or indirect sources used are acknowledged as references.

I am aware that the thesis in digital form can be examined for the use of unauthorized aid and in order to determine whether the thesis as a whole or parts incorporated in it may be deemed as plagiarism. For the comparison of my work with existing sources I agree that it shall be entered in a database where it shall also remain after examination, to enable comparison with future theses submitted. Further rights of reproduction and usage, however, are not granted here.

Neufahrn, January 10th 2020

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Abstract

At the present time, space travel is characterized by separately developed technologies of the space-traveling nations. Depending on fixed financial budgets and expensive technology companies, the developed spaceships are strongly designed just for a specific mission profile in order to reduce costs and risks as far as possible. Because of their less sustainable supply concept, these spacecraft allow only a limited mission duration and require regular supply deliveries in addition.

On the other hand side, mission periods continue to lengthen with the planned exploration of Mars, asteroids or other objects that are even more distant. These missions will require high sustainable supply concepts in order to enable autonomous and long-term life support of human mission participants. The now existing solutions do not yet meet these requirements, so the current approach of spacecraft design had to undergo a conceptual review.

The research made in the context of this work led to the design of a new generation of spacecraft, which supports with its optimized hull construction such extended long-term missions in terms of durability, variability and life support. All its embedded biological and chemical processes have, on the one hand, the primary aim to enable humans a long stay in space and, on the other hand, to be independent of an external mission supply. The performed research activities also included the necessary mechanical and energetical functions for which an extreme lifetime extension of up to 60 years has been aimed.

In comparison with the already existing designs for large-scale space stations or spacecraft having a low integration of sustainable support systems, the spaceship concept presented here offers a much higher compactness, a lower mass, and a variety of constructively implemented life support functions. The properties of this advantageous spaceship design can also be used stationary on planets, moons or asteroids, if a certain degree of gravity is available after landing.

The scaling of the described spacecraft and its contained systems is in general adjusted to supply one single person. But, however, the therefore required minimum turnovers for plant biomass, drinking water, and nitrogen would also already cover the needs of a second person. Only the preparation of breathing air needs to be enlarged, for which purpose an external source of electrical energy can be added. In order to realize even higher capable spacecraft of this type, the dimensions of the components described can be further increased, which will extend the life support to a higher number of travelers.

Zusammenfassung

In der heutigen Zeit sind Weltraumreisen durch die einzeln entwickelten Technologien der raumfahrenden Nationen geprägt. Gebunden an begrenzte finanzielle Budgets und teure Technologieunternehmen werden die derzeit entwickelten Raumschiffe stark an ein vorgegebenes Missionsprofil gebunden, um die entstehenden Kosten und Risiken weitestgehend zu reduzieren. So erlauben diese Raumflugkörper auf Grund ihrer wenig nachhaltigen Versorgungskonzepte lediglich befristete Missionszeiträume und erfordern zudem regelmäßige Versorgungslieferungen.

Jedoch vergrößern sich die Missionszeiträume mit der geplanten Erforschung von Mars, Asteroiden oder ferneren Objekten stetig, weshalb nachhaltigere Versorgungskonzepte benötigt werden, die eine autarke und langfristige Versorgung von menschlichen Reisenden ermöglichen. Die derzeitigen Lösungen genügen diesem Anspruch nicht, weshalb das aktuelle Raumschiffdesign einer konzeptionellen Überarbeitung bedurfte.

Die im Rahmen dieser Arbeit erfolgten Forschungen führten zum Entwurf einer neuen Raumfahrzeuggeneration, welche mit ihrer optimierten Hüllenkonstruktion solch ausgedehnte Langzeitmissionen in Bezug auf Haltbarkeit, Variabilität und Lebenserhaltung vielfach unterstützt. Alle darin integrierten biologischen und chemischen Prozesse haben das primäre Ziel, dem Menschen einerseits eine lange Aufenthaltsdauer im Weltraum zu ermöglichen und dabei andererseits unabhängig von einer externen Missionsversorgung zu sein. Die ausgeführte Arbeit umfasst auch die hierzu erforderlichen mechanischen und energetischen Funktionen, für welche eine extreme Verlängerung der Betriebsdauer auf bis zu 60 Jahre angestrebt wurde.

Im Vergleich zu den vorhandenen Entwürfen für groß dimensionierte Raumstationen oder Raumflugkörpern mit einer wenig nachhaltigen Systemintegration, bietet das hier vorgestellte Raumschiffkonzept eine höhere Kompaktheit, eine geringere Masse sowie eine vielfach konstruktiv unterstützte Lebenserhaltung. Die vorteilhaften Eigenschaften dieses Raumschiffdesigns sind auch stationär auf Planeten, Monden oder Asteroiden nutzbar, sofern nach der Landung ein gewisser Grad an Gravitation zur Verfügung steht.

Die Skalierung des hier beschriebenen Raumflugkörpers und seiner Einzelsysteme wurde auf die Versorgung einer einzelnen Person abgestimmt. Alle dazu erforderlichen Mindeststoffumsätze zur Nahrungs- und Trinkwasserversorgung sowie des Stickstoffkreislaufes decken jedoch auch bereits den Bedarf einer zweiten Person. Dazu muss für die Atemluftaufbereitung einzig eine externe elektrische Energiequelle ergänzt werden. Zur Realisierung noch leistungsfähigerer Raumflugkörper dieser Bauart kann die Dimensionierung der beschriebenen Komponenten weiter vergrößert werden, um die Versorgung auf weitere Reisende zu erweitern.

Contents

List of Figures

List of Tables

List of Abbreviations

Introduction

1. Microbiology as a Driver for an Organically Integrated Spaceship Concept

2. Outer and Inner Structure of a Self-Sufficient Spacecraft

2.1 A basic Hull Design of a Gravity Supporting Spacecraft

2.2 Inner Spaceship Structures for Functional Purposes

2.3 Hull Wall Construction

2.3.1 Thermal Hull Compensation Flow

2.3.2 Inner Spaceship Walls and Floors

2.3.3 Planking Materials and Weight of the Spaceship Hull

2.3.4 Implementation of Hull Leadthroughs

2.3.5 Meteorite Protection Fabric

2.3.6 Thermal Hull Insulation

2.3.7 Radiation Protection Measures

2.3.8 Qualitative Hull Checks

3. Systems for Life Support

3.1 Plant Species for Space Planting

3.2 Hydroponic Planting

3.3 Nutrient Solution Management

3.4 Nutrient Solution Circulation

3.5 Illumination of the Plantings

3.6 Photosynthetic Respiration Air Regeneration

3.7 Respiration Gas Pressure Changes

3.8 Human Nutrition and Planting Management

3.9 Salt Extraction

3.10 Drinking Water Condensation

3.11 Air Circulation Management

4. Systems for Energy Supply and Organic Material Processing

4.1 Internal Energy Supply

4.1.1 Bioreactor Units to the Degenerative Fermentation

4.1.2 Biogas Storage Tanks

4.1.3 Methane Gas Reformer Units

4.1.4 Overflow Lifter Pump

4.1.5 Simplified Hydrogen Fuel Cells

4.2 External High Energy Sources

4.2.1 Solar-based Energy Generation

4.2.2 Radioisotope Generator

4.2.3 Cold Fusion Reactor

4.3 External Material Collection

4.3.1 Hydrodynamic Material Lock

4.3.2 Static Charge Generator

4.4 Energy Dispatching Nets

5. Simplified Apparatuses for Electro Mechanics, Navigation and Spacecraft Propulsion

5.1 Internal Drives, Environment Sensors and Navigation Solutions

5.1.1 Hydromagnetic Bearings, Floating Direct Current Motors and Magnetic Gearwheels

5.1.2 Navigation Projection System

5.1.3 Environment Sensors and Control Instruments

5.1.4 Optical Display Scanning and Rotation Balancing

5.1.5 Antennas and Radio Communication System

5.2 Spaceship Propulsion

5.2.1 Space Engine Suspension

5.2.2 Review of alternative existing Propulsion Solutions

5.2.3 Centrifugal Mass Space Engine

5.3 Personal Living Space

6. On Board Software

6.1 Electronics Hardware

6.2 Computer Operating System

7. Conclusions

Acknowledgements

Bibliography

List of Figures

Fig. la: Top view of the outer hull structure

Fig. lb: Side view of the outer hull structure

Fig. lc: Rear view of the outer hull structure

Fig. Id: Single frame profile with size ratio

Fig. 2: Mounting of the landing gear

Fig. 3a: Top view of the inner structure

Fig. 3b: Side view of the inner structure

Fig. 3c: Rear view of the inner structure and the MCB

Fig. 4: Circulation of the thermal compensation flow through a spaceship segment

Fig. 5: Insulation and radiation shielding layers of the spaceship hull

Fig. 6: Pivoting mechanism of the planting racks

Fig. 7: Cross section of a hydroponic planting channel

Fig. 8: Rate of ammonium to nitrate conversion and following denitrification

Fig. 9: Cut view of a nutrient solution transport channel for variable gravity

Fig. 10: Archimedean screw pump for pumping the nutrient solution

Fig. 11: Diagram to the growth rate, light stick distance and illumination intensity

Fig. 12: Influence of the ambient air by the oxygen, carbon dioxide and nitrogen cycle

Fig. 13: Cut view of two water condensers with an underlying bioreactor-fuel-cell-unit.

Fig. 14: Cut view of ventilation unit with floating direct current motor

Fig. 15: Air flows in the concept spaceship

Fig. 16: Arrangement of the bioreactor-fuel-cell-units

Fig. 17: Cut view of a bioreactor

Fig. 18: Cut view of a biogas tank

Fig. 19: Counterflow reformer with inlet funnel for hydrogen production

Fig. 20: Cut view of the overflow lifter pump

Fig. 21: Single cell of a fuel cell block

Fig. 22: Integration of the radioisotope generators

Fig. 23: Principle of the electrostatic nuclear fusion

Fig. 24: Principle of an electrostatic acid fusion

Fig. 25: View of the MCB

Fig. 26: Hydrodynamic material lock

Fig. 27: Cut view of the floating direct current motor

Fig. 28: Circuit of the floating direct current motor

Fig. 29: Cut view of the nutrient solution pump bearing

Fig. 30: Functional scheme of a magnetic gear

Fig. 31: Navigation projections on the CINA

Fig. 32: Arrangement of the navigation room

Fig. 33: Arrangement of the CINA instruments

Fig. 34: Sensor arrangement for movement detection

Fig. 35: Denitrification and balancing tank system

Fig. 36: TABAS/LCP computer simulation

Fig. 37: Transmitting- and receiving antennas at the spaceship front

Fig. 38: Side view of a gravitation pendulum

Fig. 39: Gravitation pendulum endpoints

Fig. 40: Principle of a mass-centrifugal engine

Fig. 41: Screenshot of a CLEO application

Fig. 42: CLEO thinking process

List of Tables

Table la: Material list outer frame

Table lb: Material list inner structure

Table lc: Material list outer planking

Table Id: Material list inner planking

Table 2: Light intensities of the planting lights, depending on the growth height

Table 3: Plant density and biomass portions

Table 4: Oxygen and carbon dioxide balance

Table 5: Daily calorie requirement of a person within the concept spaceship (BMR = 49 kcal/h)

Table 6: Daily nutrient supply of a space traveler

Table 7: Thermal energy balance

Table 8: Internal electrical energy balance

Table 9a: Sensors and controls for flight operations

Table 9b: Sensors and controls for the environment

Table 9c: Sensors and controls of the power supply

Table 10: Sensor detection of celestial objects

Table 11: Composition of the spaceship mass

Table 12: Energy demands of the CLEO system

Table 13a: Threshold variables of the CLEO kernel

Table 13b: Example parameter of a logic word

Table 13c: Logic connections of single logic table entries

List of Abbreviations

General abbreviations:

Spaceship components:

Spaceship circuits:

Functional units:

Introduction

Space flight raises a great fascination on us humans since its origin. And even in the days before, futurologists and scientists of many countries were planning and describing journeys to far distant planets, asteroids, or solar systems. At all these times, such thoughts were influenced by the available technical possibilities, whereby all developed exploration plans had to be rejected soon or later.

Only today, for the first time in history, the available technologies are so advanced that enlarged space travels seem to be possible. Having now this technical opportunities, mission objectives like a manned permanent lunar base, asteroid visits, or a flight to Mars are coming more and more into the reach of mankind. These upcoming long space flights will require various innovative and sustainable spacecraft system solutions for a large number of supply issues, which then have to be integrated into a universal spaceship design. All these individual solutions must be properly dimensioned and be balanced to each other, so that – depending on the mission duration, the mission target, and the number of space travelers – closed material and energy cycles are created. Moreover, require such manned long-term missions a higher consideration of human kind of living and the physiological needs of all embedded organisms to survive such journeys as healthy as possible.

Due to the lack of super-fast space engines, whose technology is unlikely to become real in the foreseeable future, the idea of generation ships, as they were conceived by the physicist John Desmond Bernal in the 1920s, are probably the most technically plausible method to make a journey to destinations outside our solar system (Bernal et al. 1929). Bernal's vision of a multi-hundred-meter-long, rotating spaceship cylinder, which could be used as a permanent home for tens of thousands of people, embodies already the basic idea of the integration of sustainable life support components into a permanently used spacecraft.

The design concept presented here, also takes up this approach and combines many miniaturized and simplified spaceship components, making the spacecraft based on it smaller and – with a reduced crew – also cheaper to build and maintenance.

During the development of this design concept, varied research activities have been executed since 2007, out of which the results are summarized in this document. The experiments for building up a data basis to the different topics of spaceship design, support the made assumptions with verifiable results and thus could be used for a detailed simulation of the